Sealing bead

ABSTRACT

Fuel system components for vehicles may be made from polyethylene components which are typically blow molded. To inhibit fuel vapour permeation, the polyethylene is often co-extruded into a parison with the parison comprising a barrier layer. Upon trimming flash or in the mold closure itself, the barrier layer may be ruptured. Sealing of areas of discontinuity in the fuel system component to inhibit hydrocarbon vapour pass through is achieved by sealing the area of barrier discontinuity with a sealing bead which has the necessary barrier properties. The barrier properties may be inherent in the sealing bead material or in a barrier layer extruded into the sealing bead.

This application is a divisional of U.S. application Ser. No. 09/512,366filed Feb. 25, 2000, now U.S. Pat. No. 6,467,643.

FIELD OF THE INVENTION

This invention relates to fuel system components and in particular toplastic structures such as fuel tanks and the like which may be madeusing blow molding techniques. In particular, the invention relates to amethod and structure for sealing such blow molded fuel system componentsto further inhibit hydrocarbon vapour permeation through the finishedstructure.

BACKGROUND OF THE INVENTION

Hydrocarbon containing fuels such as gasoline are the most common powersource for internal combustion engines. Gasoline must be carried by thevehicle, usually in a fuel tank. Heretofore fuel tanks have beenmanufactured from metal. More recently however, much work has been doneon fuel tanks made from plastic resins, typically polyethylene.Polyethylene is a very suitable material for making fuel systemcomponents such as tanks in that it is readily moldable using blowmolding techniques. However, it has been determined that fuel vapour canpermeate through the wall of a fuel system component such as a fuel tankwhen the wall is manufactured solely from polyethylene. In order toprovide suitable anti-permeation characteristics, more complex wallstructures for such fuel system components have been developed. In ourco-pending patent application Ser. No. 09/192,295 filed Nov. 17, 1998,the disclosure which is herein incorporated by reference, there is adiscussion of a multi-layer conduit. Such conduits are readilymanufacturable using blow molding techniques.

In the blow molding technique, a parison is extruded from an extrusionhead. The parison is normally allowed to hang vertically from theextrusion head as the correct amount of parison to make the desired partis extruded. The parison is placed between the open portions of a blowmolding mold. The blow molding mold is then closed around the parisonand the parison is pinched off at the top and bottom. A convenientstructure, typically a blow molding needle, pierces the wall of theparison and blowing gas under pressure is introduced into the interiorof the parison. The parison which at that stage is hot and still quiteflowable is expanded outwardly by the blowing gas and the shape of thecavity in the blow mold determines the exterior configuration of theblow molded part. The blow molded part then has a wall thickness whichis substantially uniform around the dimension of the part, subject onlyto certain thinning of the parison as it is stretched to meet theconfiguration of the mold cavity.

Plastic molded fuel tanks have now proven to be commercially acceptableon incorporation of some means to control permeation. Typically, thepermeation can be controlled by barrier layers such as a layer ofethylene vinyl alcohol copolymer (EVOH) which is incorporated into amulti-layer parison and wall structure. Typically, in order to adherethe EVOH layer, adhesive is supplied to either side of the EVOH barrierlayer as the barrier layer is extruded from the extrusion head.Typically, the adhesive attaches the EVOH layer to an outer layer ofpolyethylene and an inner layer of polyethylene. Either or both of thepolyethylene layers may include either virgin material or scrap regroundpolyethylene material. Where required by the conditions, the inner layerof the fuel system component may also be modified so as to conductelectricity. This helps provide an electrical path to bleed off staticelectricity which might be generated in or around the fuel stored in thefuel system component. All of the various layers are simultaneouslyextruded through a multi channel extrusion head to produce a parisonready for molding.

While tanks of the type described generally above are proving quitesatisfactory, there is a continuing need to further reduce thepossibility of permeation of fuel vapours from fuel system components,in particular gasoline tanks. It has been discovered that the pinch offarea which occurs in the molding operation may be a source of fuelpermeation. This occurs because of breach or exposure of the barrierlayer in the pinching process or in the subsequent process of flashremoval.

Another area of fuel vapour permeation is through other fuel systemcomponents which may be attached to a tank such as flanges, pipenipples, sender units flanges, fuel pump flanges and the like. When aflange is made from polyethylene or other material that is thermallyfusible to the tank or fuel system component, that flange itself mayprovide a discontinuity in the barrier quality of the tank and thenpresent a path for fuel vapour permeation.

Accordingly, there is a need to have a further improved fuel systemcomponent in which the component is better sealed to further inhibitfuel vapour permeation.

In accordance with one aspect of this invention, a fuel system componentfor a vehicle comprises a wall structure wherein at least one portion ofthe wall structure includes a barrier layer for inhibiting permeation offuel vapours through the wall structure of the fuel system component.The fuel system component has at least one area of barrierdiscontinuity. The fuel system component includes a bead which comprisesmaterial for inhibiting permeation of hydrocarbon vapours and the beadoverlies the area of barrier discontinuity. The outer layer of the wallstructure and at least a portion of the bead are comprised ofcomplimentary heat fusible materials for sealing the bead to the wallstructure over the area of barrier discontinuity.

In another aspect of the invention, a process for inhibiting fuel vapourpermeation in a component for storing or conveying hydrocarbon fuels,where the component includes an area of barrier discontinuity includesthe step of covering the area of barrier discontinuity of the componentwith a sealing bead. The sealing bead includes a barrier element forinhibiting fuel vapour permeation therethrough.

In a further aspect of the invention, the invention comprises a processfor producing a fuel system component comprising the following steps,extruding a multi-layer parison from an extrusion head wherein theparison comprises a barrier layer for substantially inhibitingpermeation of fuel vapours. The parison is enclosed in a partible blowmold. The parison is blow molded and cooled to produce a molded product.The molded product is removed from the mold. The finished molded productwill have at least one area of barrier discontinuity. A bead of materialis placed on the molded product at the area of barrier discontinuity.The material of the bead comprises a barrier property for substantiallyinhibiting permeation of fuel vapours through the bead.

The invention will now be more clearly understood by reference to thefollowing drawings, which illustrate a preferred embodiment of theinvention, and in which:

FIG. 1 illustrates a general arrangement of a parison and blow moldprior to mold closure;

FIG. 2 illustrates a mold and parison of FIG. 1 after the mold has beenclosed;

FIG. 3 illustrates diagrammatically a gasoline tank which may beproduced in the mold of FIGS. 1 and 2;

FIG. 4 is an enlarged view of the pinch off portion of the gasoline tankof FIG. 3 illustrating the multi-layer structure in the area of thepinch off;

FIG. 5 is a view similar to FIG. 4 illustrating a cross-sectional areaof the pinch off which has been sealed in accordance with the presentinvention;

FIG. 6 is a view similar to FIG. 4 of the sealed portion of the pinchoff of the gasoline tank in accordance with an embodiment of thisinvention;

FIG. 7 is a view similar to FIG. 6 but showing an alternate embodimentof the invention;

FIG. 8 is a perspective view of an apparatus for applying a sealing beadin accordance with the invention, and

FIG. 9 is a cross-section of a further embodiment of the invention.

FIG. 1 illustrates the general arrangements of components in typicalblow molding procedure. A blow mold 10 comprises complimentary moldportions 12 and 14. The mold portions 12 and 14 are movablehorizontally, as shown in FIG. 1, from an open position to a closedposition as shown in FIG. 2. When the mold portions 12 and 14 are in theopen position, a parison 16 is extruded from an extrusion head (notshown). The parison will hang substantially vertically from theextrusion head. When the parison has been extruded and has theappropriate length, the mold portions 12 and 14 are closed. The closedconfiguration is illustrated in FIG. 2.

With reference to FIG. 2, it will be noted that there is a small portionof the parison indicated diagrammatically above the mold 10 as 20. Therewill also be a small amount of parison material extending beyond themold indicated generally at 22. In order to achieve typical blowmolding, the parison must form an air tight enclosure. Thus, the moldportions 12 and 14 pinch the area tight. The area of pinch typicallywill occur substantially adjacent the upper and lower portions of themold portions 12 and 14, but may occur elsewhere in the parisondepending upon the shape of the parison and other moving components suchas slides and the like which may be components of the mold portions 12and 14. For purposes of simplicity and explaining this invention, itwill be assumed that the only pinch of the parison 16 which occurs issubstantially adjacent the upper and lower surfaces of the mold 16 aspictured in FIG. 2.

Upon cooling of the parison material, the mold portions 12 and 14 areagain moved to the open position as illustrated in FIG. 1 and thefinished molded part is removed from the mold. FIG. 3 illustrates a fueltank which may be produced according to the FIGS. 1 and 2. The fuel tankindicated generally at 30 has an upper surface 32, and side walls 34 and36.

In the areas where the parison is pinched, there will be a ridge ofmaterial upstanding from the general plane of the surface 32. This ridgeof material is identified as 40. The ridge of material 40 may extendsubstantially across the entire upper surface 32.

The fuel tank 30 will also have a lower surface generally opposite tothe upper surface 32. While this surface is not visible in FIG. 3, theedge of that surface adjacent wall 32 is visible. There will also be aridge of material pinched off as illustrated at 42. The ridge 42 willextend substantially along the bottom surface of the fuel tank 30.

The ridges 40 and 42 are substantially similar. They need not have thesame configuration as the configuration will be determined by the moldcharacteristics and the location of the parting line between the moldhalves. These need not be the same at the top and bottom of the fueltank. Typically, although not necessarily, the ridges 40 and 42 arereferred to as “flash” and are removed by cutting off excess material.

We have determined that the ridges 40 and 42 are sites for possiblepermeation losses of fuel vapour from the fuel tank 30. Permeation canoccur through the walls of the fuel tank 30 if the fuel tank 30 is madesimply of polyethylene. By using a multi-layer parison incorporating abarrier layer, the permeation losses from the fuel tank are verysubstantially inhibited as compared to a fuel tank manufactured from amaterial not having the appropriate barrier layer characteristic.However, the ridges 40 and 42 are problematic areas in the tank causedas it is produced in the mold 10 or during flash removal. This isbecause the parison material must flow in the area of the pinch and thebarrier layer may be ruptured or exposed to air either during thepinching operation forming the ridge 40 and 42 or during the flashremovable stage which is typically conducted on the part 30 after itsremoval from the mold 10.

If the barrier layer becomes discontinuous because of rupture orremoval, then there is a narrow path for hydrocarbon vapours to passalong the polyethylene and out through the area where the barrier layerhas been breached. Polyethylene will stop the passage of any liquid butwill not sufficiently inhibit permeation of hydrocarbon vapours.

Even if the barrier layer is not itself breached, the continuity of theouter materials of the multi-layer fuel tank may be removed during theflash removal process to the point that the barrier layer is exposed toair. Once a barrier layer of material such as EVOH is exposed to ambientair, the barrier layer will absorb moisture from the air. Upon absorbingmoisture from ambient air, the barrier qualities of the EVOH begin todeteriorate. Ultimately the barrier material will cease to haveacceptable barrier properties and fuel vapour will be able to permeatethrough the polyethylene and the deteriorated barrier material. Theseareas in which the barrier layer has been breached or exposed arereferred to herein as areas of barrier discontinuity.

FIG. 4 is a diagram showing an enlarged cross-sectional view through aridge 40 after a fuel tank 30 is removed from a mold 10. In the diagram,the polyethylene inner and outer layers are identified as 46 and 48respectively. The EVOH barrier layer is illustrated at 50, while theadhesive layers are shown at 52 and 54. Adjacent the apex 60 of theridge 40, it will be observed that there is an area of barrierdiscontinuity. As shown in FIG. 4, the ridge 40 thus provides apermeation route which is not inhibited by a barrier, through the apexportion 60.

FIG. 5 illustrates a means for sealing the ruptured ridge 40 adjacentthe apex 60. In FIG. 5, there is illustrated a sealing 70 which overliesthe ridge 40. The sealing 70 serves to seal the ridge 40. The purpose ofthe sealing 70 is that it replace the function of the ruptured barrierlayer 50. In order to do this, the sealing 70 must itself providesuitable barrier quality. In addition, the sealing 70 is sealed to thefuel tank 30 on either side of the ruptured portion of the barrier 60.Small air voids shown at 71 and 73 may exist at either edge of the ridge40. The bead overlies the area of barrier discontinuity and the bead isthermally fused to the tank wall 30 on either side of the ridge 40.

The sealing bead 70 may itself be a multi-layer extrusion. This isillustrated diagrammatically in FIG. 6. Similar to the material fromwhich the fuel tank 30 is constructed, the sealing 70 may also have aninner layer of polyethylene material 72 which may be either virginpolyethylene, reground polyethylene or mixtures. This would then befollowed by an inner adhesive layer 74, an EVOH or other barrier layer76, an outer adhesive layer 78 and an outer layer 80 of polyethylenewhich, again, may be either virgin polyethylene, reground polyethyleneor mixtures. The inner and/or outer layer 72 and 80 of polyethylene ofthe sealing 70 will then be heat sealable to the outer polyethylenelayer of the tank 30 to comprise a seal.

An alternative material for the barrier 70 is illustrated in FIG. 7. Thesealing bead 90 illustrated in FIG. 7 is comprised of material which isitself a barrier and thus does not need to be a multi-layer material.Materials such as the resin sold by the Dupont company under the trademark SELAR RB is now sold as a barrier resin for plastic fuel tanks. Thebarrier resin sold by Dupont is said to be a pellet blend of a nyloncopolymer and a proprietary adhesive for nylon and high densitypolyethylene. The SELAR material provides the required barrierperformance to reduce evaporative emissions through the bead. Inaddition, the SELAR material is compatible for thermal welding topolyethylene.

Most conveniently, the sealing bead may be applied to the ridges 40 and42 after any flash is removed by means of an extrusion die 100 which maybe connected to a flexible conduit 102 (see FIG. 8). The extrusion head100 may extrude the sealing bead 70 or the sealing bead 90 through asubstantially V-shaped slot 104 over the raised ridges 40 and 42. Theextrusion head may be moved by a robot controlled arm 106 to lay a beadover the ridges 40 and 42 after the flash removal process has beencompleted.

If the sealing bead is in the form of an inherent barrier material suchas SELAR then a single conduit carrying SELAR to the extrusion head maybe used. If a multi-layer material is to be used such as shown in FIG.6, then the head 100 must be equipped for multi-layer extrusion. Thematerial for the head 100 may be supplied by a conduit or conduits 102or the material may be preformed in a stick-like bar and fed to the slot104 in a manner similar to a glue gun using glue sticks.

While the invention herein has been discussed in connection with a fueltank 30 having a pinch off or bead formed at the upper and lowersurfaces, the technology is applicable to any areas in which there hasbeen a breach of the barrier property of a multi-layer structure. Thismay occur where the parison material is pinched by moving slides orother sub-components of the mold portions or where the barrier layer isotherwise breached during flash removal operations and the like. Also anarea of breach may occur when another fitting is attached to a componentwhich has barrier qualities.

An example of this occurrence may be where a fuel tank is manufacturedhaving the requisite barrier qualities. However, after manufacture, itmay be that several holes are cut into the tank. Such holes may be forlocating the fuel sender unit and for the location of pipe nipples, rollover valves and other similar fittings that are often associated withfuel system components, in particular, fuel tanks. Typically, when othersuch fittings are incorporated in a fuel tank, the necessary size ofholes is cut or punched or otherwise formed in the tank. The fuel systemfitting, for example, a pipe nipple, will then be welded to the tank.The pipe nipple for the tank may have a flange for welding to the tank.The pipe nipple may be made from material which has sufficient barrierqualities such as nylon, but the flange to be used to weld the pipenipple to the tank must be thermally compatible for fusing to the tankmaterial. In such cases, it is known to use a modified polyethylene thatis weldable to standard polyethylene as well as to other polymericmaterials such as nylon.

FIG. 9 illustrates diagrammatically in cross-section, the connection ofa pipe nipple to a tank 30. A hole 110 has been formed in the wall ofthe tank for communication with a pipe nipple illustrated generally at120. The pipe nipple 120 may be advantageously formed from nylon orother material which is creep resistant so that a flexible conduit maybe tightly clamped to the end portion 122 of the pipe nipple 120. Thetank 30 illustrated in FIG. 9 may be formed from a multi-layer extrusionas discussed previously. Thus, the tank 30 comprises a barrier layer notshown in FIG. 9, which will inhibit the passage of hydrocarbon vapoursthrough the wall of the tank 30. The tank 30 may have an outer layerwhich is comprised of polyethylene material. In order to join the nylonpipe nipple 120 to the tank 30, a washer-shaped flange element 130 isformed. The flange element 130 has a central aperture 132 which may bethe same size and configuration as the hole 110 or different as requiredby the configuration of the pipe nipple 120. Preferably the flangeelement 130 is formed of a modified polyethylene material. The modifiedpolyethylene material may be welded both to the nylon of the pipe nipple120 and to the outer surface of the multi-layer tank 30.

In the configuration as shown in FIG. 9, fuel vapours can pass upwardlythrough the hole 110 in the wall of the tank 30. Fuel vapour could thentravel horizontally in FIG. 9 through the flange element 130 enteringthe flange element 130 at the aperture 132. This then provides anotherpath for fuel vapour permeation through the flange element 130.

In order to further inhibit fuel vapour permeation through the flangeelement 130, a sealing bead 140 is laid down over the flange element130. The sealing bead 140 is similar to the sealing bead 70 or thesealing bead 90 discussed above, that is, the sealing bead 140 may beformed from a multi-layer material including a barrier layer such assealing bead 70 or may be formed from a material having inherent barrierproperties similar to sealing bead 90.

The flange element 130 represents an area of barrier discontinuity inrespect of the tank 30. The sealing bead 140 overlays that area ofbarrier discontinuity and inhibits passage of hydrocarbon vapoursthrough the area of barrier discontinuity represented by the flangeelement 130.

In FIG. 9, the area of barrier discontinuity is shown in the form of aseparate flange element 130. Various other types of barrierdiscontinuity may also exist in the form of integral flanges or otherlike structures used to attach things to a tank 30. In each case, a fuelsystem component added to the tank may comprise at least a portion whichdoes not include any form of barrier layer. In each case that portionthen represents an area of barrier discontinuity. Fuel vapour permeationcan be inhibited by overlying such component or the critical portion ofsuch component to cover off the area of barrier discontinuity.

A bead 140 may be placed using a mechanism as shown in FIG. 8. In FIG.8, the head 140 is shown as having a V-shaped slot 140 through which thematerial is extruded. A V-shaped slot is particularly suited to coveringseams and the like as discussed in connection with FIGS. 4, 5, 6 and 7.However, other configurations for the slot 140 may be utilized dependingupon the configuration and size of the area of barrier discontinuitywhich is to be covered by the sealing bead. As shown in FIG. 9, thesealing bead need not be V-shaped and may have any convenient shape aslong as the edges of the bead are fused to the structures which have thenecessary barrier qualities to eliminate the easy path for fuel vapourpermeation represented by the area of discontinuity.

The invention has been discussed herein in association with preferredembodiments of the invention which are illustrative only. The full scopeof the invention is set out in the following claims.

I claim:
 1. A process for producing a fuel system component comprising,extruding a multi-layer parison from an extrusion head, said parisoncomprising a barrier layer for substantially inhibiting permeation offuel vapours, enclosing said parison in a partible blow mold, blowmolding said parison and cooling said parison to produce a moldedproduct removing said molded product from said mold, said fuel systemcomponent having at least one area of barrier discontinuity, placing abead of material on said fuel system component at said area of barrierdiscontinuity, and wherein said material of said bead comprises abarrier property for substantially inhibiting permeation of fuel vapoursthrough said bead.
 2. The process of claim 1 wherein said processfurther comprises removing flash from said molded product after saidmolded product is removed from said mold.
 3. The process of claim 2wherein said bead is placed at said area of barrier discontinuity bymeans of a robot guided arm.
 4. The process of claim 1 wherein saidcomponent is a fuel tank.
 5. The process of claim 1 wherein said bead isformed from material extruded from an extrusion head.
 6. The process ofclaim 1 wherein said bead is a multi-layer material comprising at leastone layer for substantially inhibiting permeation of hydrocarbonvapours.
 7. The process of claim 1, wherein said barrier fuel systemcomponent includes a polymeric fitting and said fitting comprises anarea of barrier discontinuity.
 8. A process for producing a fuel systemcomponent intended for storing or conveying hydrocarbon fuel comprising,extruding a multi-layer parison from an extrusion head, said parisoncomprising a barrier layer for substantially inhibiting permeation offuel vapours, enclosing said parison in a partible blow mold, blowmolding said parison and cooling said parison to produce a moldedproduct removing said molded product from said mold, said fuel systemcomponent having a wall structure, said wall structure including atleast one area of barrier discontinuity, placing a bead of material onthe external wall of said fuel system component over said area ofbarrier discontinuity, and fusing said bead to said external surface,and wherein said material of said bead comprises a barrier property forsubstantially inhibiting permeation of fuel vapours through said bead.9. The process of claim 8 wherein said process further comprisesremoving flash from said molded product after said molded product isremoved from said mold.
 10. The process of claim 9 wherein said bead isplaced at said area of barrier discontinuity by means of a robot guidedarm.
 11. The process of claim 8 wherein said bead is formed frommaterial extruded from an extrusion head.
 12. The process of claim 11wherein said barrier fuel system component includes a polymeric fittingand said fitting comprises an area of barrier discontinuity.